Weil-McLain 633500203 User manual

Brand: Weil-McLain

Model: 633500203

Category: Water heaters & boilers

Type: User manual

This manual is also suitable for

Aqua Pro

Part number 633-500-230/0918

• Installation

• Startup

• Maintenance

• Parts

Product Manual

PRO

This manual must only be used by a qualiﬁed heating installer/service technician. BEFORE installing, read all instructions

in this manual and all other information shipped with the water heater. Perform steps in the order given. Failure to comply

could result in severe personal injury, death or substantial property damage.

User — Read important user safety information found on page 3, page 27 and page 28. Installation and service should only be

performed by a qualiﬁed service technician. Retain this manual for future reference.

Indirect-Fired Water Heaters

Part number 633-500-230/0918

AQUA PRO

INDIRECT-FIRED WATER HEATERS — Product Manual

Please read before proceeding 3

When servicing water heater . . . . . . . . . . . . . . . . . . . . 3

Operating restrictions . . . . . . . . . . . . . . . . . . . . . . . . 3

Boiler water restrictions . . . . . . . . . . . . . . . . . . . . . . . 3

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Pre-installation 4

Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Code restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Water heater placement . . . . . . . . . . . . . . . . . . . . . . . 4

Install levelling legs . . . . . . . . . . . . . . . . . . . . . . . . . 4

Domestic water piping requirements. . . . . . . . . . . . . . . . 5

Water heater operating restrictions. . . . . . . . . . . . . . . . . 5

Boiler water restrictions . . . . . . . . . . . . . . . . . . . . . . . 5

Hot Water Can Scald! . . . . . . . . . . . . . . . . . . . . . . . . 5

Domestic water piping 6

Piping overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Recirculation 8

Maintaining domestic water temperature in the supply piping . 8

Time delay at ﬁxtures . . . . . . . . . . . . . . . . . . . . . . . . 8

Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Components required . . . . . . . . . . . . . . . . . . . . . . . . 8

Connecting to the water heater . . . . . . . . . . . . . . . . . . . 8

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Potential problems. . . . . . . . . . . . . . . . . . . . . . . . . 10

Boiler-side piping 11

Connecting to a low-pressure steam boiler 18

Filling the piping . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Boiler-side wiring and controls 20

Wiring requirements. . . . . . . . . . . . . . . . . . . . . . . . 20

Circulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Zone Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Wiring to the water heater. . . . . . . . . . . . . . . . . . . . . 20

Wiring options . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Use domestic priority . . . . . . . . . . . . . . . . . . . . . . . 20

Wiring — zoning with circulators 23

Wiring — zoning with zone valves 23

Mounting and wiring the Control - New Installations 24

Setting the Control 25

Water heater ﬁlling and start-up 26

Boiler water restrictions . . . . . . . . . . . . . . . . . . . . . . 26

Maximum boiler-side ﬂow rate . . . . . . . . . . . . . . . . . . 26

Filling the domestic water tank . . . . . . . . . . . . . . . . . . 26

Start-up and operation . . . . . . . . . . . . . . . . . . . . . . 26

Start-up checklist . . . . . . . . . . . . . . . . . . . . . . . . . 26

Water heater temperature adjustment 27

Setting the control . . . . . . . . . . . . . . . . . . . . . . . . . 27

Hot Water Can Scald! . . . . . . . . . . . . . . . . . . . . . . . 27

Water heater maintenance 28

ANNUAL start-up by qualiﬁed service technician . . . . . . . 28

Drain the water heater if necessary during shutdown periods . 28

Troubleshooting 29

Troubleshooting procedures . . . . . . . . . . . . . . . . . . . . . 29

Preparation for troubleshooting . . . . . . . . . . . . . . . . . . . 29

Replacement parts 38

Rating – Aqua Pro

Dimensions 40

Contents

Failure to adhere to the guidelines on this page can

result in severe personal injury, death or substantial

property damage.

Read all instructions before installing. Failure to follow all instruc-

tions in proper order can cause severe personal injury, death or

substantial property damage.

When servicing water heater

• To avoid electric shock, disconnect electrical supply before

performing maintenance.

• To avoid severe burns, allow water heater to cool before per-

forming maintenance.

Operating restrictions

• Maximum domestic hot water temperature: residential sizes

— 160°F, commercial sizes — 180°F. Pay attention to the

water temperature warnings throughout this manual.

• Maximum boiler water temperature — 200°F.

• Maximum working pressure for tank — 150 PSIG.

Boiler water restrictions

• Thoroughly ﬂush the boiler system (without water heater

connected) to remove sediment.

• The water heater heat exchanger can be damaged by build-up

or corrosion due to sediment.

• Boiler water (including additives) must be practically non-

toxic, having toxicity rating or class of 1, as listed in Clinical

Toxicology of Commercial Products.

• If antifreeze is used in boiler system:

• Local codes may require a backﬂow preventer on cold

water supply line.

• Use antifreeze speciﬁcally intended for hydronic heating

systems. Inhibited propylene glycol is recommended.

• Follow boiler manual instructions for antifreeze usage.

• Do not use automotive, ethylene glycol or petroleum-

based antifreeze. Do not use any undiluted antifreeze.

Location

• This water heater is not intended for outdoor installation.

• Install the water heater so if the tank or any connections

should leak, the water ﬂow will not cause damage to area

near water heater, or to lower ﬂoors of structure. When such

locations cannot be avoided, install a suitable drain pan under

water heater. Drain pans are available at your local plumbing

supply store.

• This product is designed for vertical installation only.

When calling or writing about the water

heater — Please have the water heater se-

rial number from the serial number label,

located on the back side of the water

heater, adjacent to the rating plate.

Any claims for damage or shortage in

shipment must be filed immediately

against the transportation company by

the consignee.

Hazard deﬁnitions

The following deﬁned terms are used throughout this

manual to bring attention to the presence of hazards

of various risk levels or to important information

concerning the life of the product.

Indicates presence of hazards that will

cause severe personal injury, death or

substantial property damage.

Indicates presence of hazards that can

cause severe personal injury, death or

substantial property damage.

Indicates presence of hazards that will

or can cause minor personal injury or

property damage.

Indicates special instructions on installa-

tion, operation or maintenance that are

important but not related to personal

injury or property damage.

This manual provides installation and

operation guidelines for Weil-McLain

Aqua Pro

indirect water heaters. The

installer is responsible for ensuring

that the installation complies with this

manual, the boiler manual and all ap-

plicable codes.

Massachusetts installations — The

water heater must be installed by a li-

censed plumber. The installation must

follow all Massachusetts code require-

ments. The domestic water piping must

comply with the piping shown in this

manual. See “Domestic water piping,”

page 6, for details and code requirements.

Part number 633-500-230/0918

AQUA PRO

INDIRECT-FIRED WATER HEATERS — Product Manual

Please read before proceeding

Pre-installation

Part number 633-500-230/0918

AQUA PRO

INDIRECT-FIRED WATER HEATERS — Product Manual

Figure 1 Clearance recommendations

Codes

1. Installation must conform with instructions in this

manual and, where applicable:

• local, state, provincial, and national codes, laws,

regulations and ordinances.

• in Canada — B149.1 or B149.2 Installation

Code - latest edition.

2. Aqua Pro

water heaters are exempt from ASME

Section VIII, Division 1 Code construction per

Interpretation VIII-1-86-136. Check with local

codes for applicability.

3. Where recommendations in this manual differ from

local or national codes, local or national codes take

precedence.

Code restrictions

National Standard Plumbing Code

1. Single-wall heat exchanger in water heater complies

with National Standard Plumbing Code, provided

that:

a. boiler water (including additives) is practically

non-toxic, having toxicity rating or class of 1,

as listed in Clinical Toxicology of Commercial

Products, and

b. boiler water pressure is limited to maximum 30

PSIG by approved relief valve.

Uniform Plumbing Code

1. Single-wall heat exchangers are permitted if they

satisfy all of the following requirements —

a. The heat transfer medium is potable water or

contains only substances which are recognized

as safe by the U. S. Food and Drug Adminis-

tration.

b. The pressure of the heat transfer medium is

maintained less than the normal minimum

operating pressure of the potable water system.

c. Exception: Steam complying with #a, above.

d. The equipment is permanently labeled to indi-

cate that only additives recognized as safe by the

FDA shall be used in the heat transfer medium.

2. Other heat exchanger designs may be permitted

where approved by the Administrative Authority.

Recommended clearances

Installation location must provide adequate clearances for servicing and

proper operation of the water heater. See Figure 1.

• 1” clearance is permissible to either side of water heater, but the Instruc-

tion label or other labels may be hidden.

• Top (vertical) clearance is “

A” minimum.

Clearance for the servicing the replacement Heat Exchanger are as follows:

“A” minimum

Models Aqua Pro

30 & 55 — 36”

Models Aqua Pro

80 — 48”

Models Aqua Pro

119 — 66”

Clearance to combustible materials

1. Provide at least ½” clearance between all hot water pipes and combus-

tible materials.

Water heater placement

1. Read and comply with “Location,” page 3 of this manual.

2. Select a convenient location for the water heater, based on domestic

and boiler piping hook-ups.

3. Keeping the distance between boiler and water heater short will:

• reduce piping heat loss.

• provide minimum friction loss.

Pre-installation

(continued)

Hot Water Can Scald!

• Water heated to temperature for clothes washing,

dish washing and other sanitizing needs can scald

and cause permanent injury.

• Children, elderly, and inﬁrm or physically handi-

capped persons are more likely to be permanently

injured by hot water. Never leave them unattended

in bathtub or shower. Never allow small children to

use a hot water tap or draw their own bath.

• If anyone using hot water in the building ﬁts

the above description, or if state laws or local

codes require certain water temperatures at

hot water taps, you must take special precau-

tions:

• Use lowest possible temperature setting.

• Install some type of tempering device, such

as an automatic mixing valve, at hot water

tap or water heater. Automatic mixing valve

must be selected and installed according

to valve manufacturer’s recommendations

and instructions.

• Water passing out of drain valves may be extremely

hot. To avoid injury:

• Make sure all connections are tight.

• Direct water ﬂow away from any person.

Protection must be taken against excessive tem-

perature and pressure! — Installation of a tem-

perature & pressure (T&P) relief valve (provided

with water heater) and a thermostatic mixing valve

(provided by installer) is required.

Part number 633-500-230/0918

AQUA PRO

INDIRECT-FIRED WATER HEATERS — Product Manual

Domestic water piping requirements

1. Install unions on all piping for easy removal of water heater.

2. Use dielectric unions or couplings to protect hot and cold water

ﬁttings from corrosion when connecting dissimilar materials such

as copper and galvanized iron pipe.

When the supply pressure is higher than 70 PSIG, install a pres-

sure reducing valve on cold water supply line to prevent water loss

through T&P relief valve. A thermal expansion tank is also required.

4. If the water heater will replace a tankless coil in the boiler, discon-

nect piping to coil or remove coil from boiler and replace with

a cover plate. Allow water to drain from coil.

Do not plug the

tankless coil.

Plugging tankless coil inlet and outlet will result in severe

personal injury, death or substantial property damage.

Studies have indicated that dangerous bacteria,

including

legionella pneumophila, can form in

the potable water distribution system if certain

minimum water temperatures are not maintained.

Contact your local health department for more

information.

Boiler water restrictions

1. Read the WARNINGS under “Boiler water restrictions,” page 3.

Domestic water piping

Figure 2 DHW piping

Piping overview

THERMAL EXPANSION TANK — If a

backﬂow preventer, check valve, or pres-

sure reducing valve is piped on cold water

inlet of water heater, you must install an

expansion tank on cold water supply line

to prevent normal thermal expansion

from repeatedly forcing open T&P relief

valve.

The T&P relief valve is not intended for

constant duty, such as relief of pressure

due to repeated normal system expan-

sion. Refer to expansion tank manufac-

turer’s instructions for proper sizing.

Failure to comply could result in severe

personal injury, death or substantial

property damage.

General applications

1. Figure 2 — This piping conﬁguration can be used in

most cases, except where local codes require special

components or piping not illustrated.

2. Some codes may require the items listed as optional,

such as a vacuum breaker on the inlet line, or re-

circulation piping.

Massachusetts applications

1. For Massachusetts code applications, or as

required elsewhere by local codes, install the fol-

lowing options.

a. Thermal siphon on DHW inlet and outlet.

b. Vacuum breaker on domestic water inlet line.

c. Recirculation —

Massachusetts code applica-

tions require recirculation piping or heat-traced

piping if the distance from the water heater to

the furthest ﬁxture exceeds 100 feet. See page 8

for details.

Figure 3

Piping connection sizes

Model

Aqua Pro

Connections

(inches MNPT)

DHW

in/out

Boiler

water

in/out

¾¾

1 ½ 1

119

1 ½ 1

Part number 633-500-230/0918

AQUA PRO

INDIRECT-FIRED WATER HEATERS — Product Manual

Domestic water piping

(continued)

Part number 633-500-230/0918

AQUA PRO

INDIRECT-FIRED WATER HEATERS — Product Manual

LEGEND for Figure 2, page 6

Domestic water supplied to ﬁxtures that could pose

an injury hazard due to high temperature, such as

showers and faucets, should be equipped with a

temperature regulating device, such as an anti-scald

mixing valve

When the supply pressure is higher than 70 PSIG,

install a

pressure reducing valve on cold water

supply line to prevent water loss through T&P relief

valve. A thermal expansion tank is also required.

This symbol, where used in this manual, indicates the

item is required by Massachusetts code.

This symbol indicates the item is optional, unless

required by applicable codes.

1 Domestic cold water inlet connection — see Fig-

ure3,page6 for size

2 Domestic hot water outlet connection — see Fig-

ure3,page6 for size

3 Boiler water inlet to coil — see Figure3,page6 for size

4 Boiler water outlet from coil — see Figure3,page6 for

size

5 Drain valve — provided by installer

• Install a drain valve on the DHW inlet to the water heater

as shown.

6 Piping from drain valve

• Pipe from drain to ﬂoor drain, if available.

T&P relief valve — supplied with water heater

• Use only the T&P valve supplied with the water heater.

See Replacement parts for part number.

• Install the T&P relief valve in the top left tapping, as

shown.

T&P relief valve discharge piping —

• must be made of material serviceable for temperatures

of 250°F or greater.

• must be directed so that hot water ﬂows away from all

persons.

• must be directed to a suitable place for disposal.

• must be installed so as to allow complete draining of the

T&P relief valve and discharge line.

• must NOT be excessively long — using more than 2

elbows or 15 feet of piping can reduce discharge capacity.

• must NOT be directly connected to a drain — terminate

discharge piping within 6” from ﬂoor — refer to local

codes.

• must NOT be plugged, reduced or restricted.

• must NOT be subjected to freezing.

Do not install any valve between T&P relief valve and

tank connection, or on T&P relief valve discharge

piping. Do not plug T&P relief valve or its discharge

piping. Improper placement and piping of T&P re-

lief valve can cause severe personal injury, death or

substantial property damage.

Temperature - Electronic Control

10 Mixing valve — — RECOMMENDED

• See Replacement parts for thermostatic mixing valves

available from Weil-McLain.

Domestic cold water supply

When the water supply pressure is higher than

70 PSIG, install a pressure-reducing valve on the cold

water supply line to prevent leakage from the T & P

relief valve. A thermal expansion tank is also required.

Domestic mixed-temperature water supply to

system

(when used — requires mixing valve)

13 Domestic high-temperature hot water supply to

system

14 Heat trap loops (12” minimum) —

15 Isolation valves

16 Thermal expansion tank —

• REQUIRED if cold water line is equipped with a backﬂow

preventer or pressure reducing valve — see

EXPANSION

TANK WARNING

on page 6.

Shock arrester —

Dishwashers, clothes washers, and fast-closing positive

shutoff valves incorporated in the system all contrib-

ute to creating water shock. Install a water hammer

arrester to prevent damage to pipes and appliances.

See control manufacturer’s instructions for applica-

tion and installation.

Unions

• Use dielectric unions or couplings to protect hot and cold

water ﬁttings from corrosion when connecting dissimilar

materials such as copper and galvanized iron pipe.

Backﬂow preventer — — — (required

for Commonwealth of Massachusetts)

20 Vacuum breaker —

21 Pressure reducing valve —

• REQUIRED when the supply pressure is higher than

70 PSIG — A thermal expansion tank is also required.

Recirculation

Massachusetts code applications require recircu-

lation piping or heat-traced piping if the distance

from the water heater to the furthest ﬁxture exceeds

100 feet.

Maintaining domestic water

temperature in the supply piping

1. Recirculation is used to reduce wait time for water use, to

minimize hot water and energy waste caused during the

waiting period, and to prevent degradation of the system

supply water temperature. ASPE recommends recirculation

when the distance from the water heater to the furthest ﬁx-

ture exceeds 100 feet or the time lag for hot water to reach a

ﬁxture(s) exceeds 30 seconds.

2. Consult local codes and American Society of Plumbing

Engineers (ASPE) Domestic Water Heating Design Manual,

1998, for further information.

Time delay at ﬁxtures

1. Figure 4, page 9 is from the ASPE Domestic Water Heating

Design Manual, 1998. It shows the time required for usable

hot water to arrive at a ﬁxture based on the ﬁxture ﬂow rate

(available from industry and manufacturer’s data) and the

length and diameter of the dead-end branch pipe supplying

the ﬁxture.

2. The time lag should generally not exceed 30 seconds.

3. For residential and ofﬁce applications, the owner may prefer

a limit of 10 seconds.

4. You can use Figure 5 as a guide to determining the location

of circulation return lines relative to ﬁxtures.

Balancing

1. When multiple branches are connected to the supply pip-

ing, each branch must be connected to the recirculation

system.

a. At each of these connections to the return piping, install

shutoff valves, a ﬂow metering device, check valve and a

strainer as shown in Figure 4, page 9.

b. Check local codes for specific installation require-

ments.

2. These branches must be balanced to prevent pipe erosion

and unacceptable time delays at some ﬁxtures.

3. Balancing options include circuit setters, memory stop valves

or factory preset devices (with ﬂow metering provision in

the piping).

Components required

1. For residential applications, consult circulator manufacturer’s

data for circulator selection and additional components

required.

2. On most commercial systems, install the devices shown in

Figure 5, page 9, and any other devices or piping methods

required by local codes.

a. The check valves are required to prevent ﬁxtures from

taking hot water through the return lines.

b. Shutoff valves are needed to allow cleaning and replacing

balancing devices.

c. Include strainers to remove sediment which could

damage the circulator and / or affect the ﬂow balancing

devices.

3. Size the circulator and piping based on the temperature drop

allowed between the water available at the water heater and

the water delivered at the ﬁxture.

a. The return piping will almost always be smaller than the

supply piping, but should never be smaller than ½” to

prevent problems with the circulator.

4. Make provision for removal of air in all return lines. Where

the returns cannot be vented by topmost ﬁxtures in the

system, install automatic air venting at the top of the return

piping.

Connecting to the water heater

1. Install the domestic water components as shown in Fig-

ure 2, page 6.

2. See Figure 6, page 10 for the piping required to the water

heater.

— Continued on page 10 —

Part number 633-500-230/0918

AQUA PRO

INDIRECT-FIRED WATER HEATERS — Product Manual

Recirculation

(continued)

Part number 633-500-230/0918

AQUA PRO

INDIRECT-FIRED WATER HEATERS — Product Manual

Time in seconds required to get hot water at ﬁxture (from ASPE)

Fixture ﬂow rate (GPM) - 0.5 1.5 2.5 4.0

Piping length (feet) - 10 25 10 25 10 25 10 25

Copper pipe ½” 25 63 8 21 5 13 3 8

¾” 48 119 16 40 10 24 6 15

Steel pipe ½” 63 157 21 52 13 31 8 20

¾” 91 228 30 76 18 46 11 28

CPVC pipe ½” 64 159 21 53 13 62 8 20

¾” 95 238 32 79 19 48 12 30

NOTE: Select branch size and length for less than 31 seconds delay.

Figure 4 Time lag to obtain hot water at ﬁxture for branch lengths of 10 and 25 feet (ASPE Domestic Water Heating Design Manual)

Figure 5 Recirculation components

Recirculation

(continued)

Figure 6 Recirculation piping

Components

Circulator (Figure 6, item 1)

1. Little ﬂow is required to maintain a temperature

in the piping.

2. Size of circulator depends on minimum ﬂow re-

quirements of the tempering valve.

3. Minimum ﬂow rates of the tempering valve must

be maintained.

Aquastat (Figure 6, item 2)

1. Used to control the on-off position of the circula-

tor. Aquastat is set 5° to 10° lower than mixed water

outlet of the mixing valve (#7).

2. The circulator cannot run continuously as bypass

through the mixing valve will eventually allow the

temperature on the piping to climb to the water

heater temperature during draw periods.

Check valves (Figure 6, items 3–6)

1. Assure the ﬂow of water in one direction.

2. Each check valve functions as follows:

a. #3 and #4 prevent bypass in the event of pres-

sure drop.

b. #5 prevents thermal siphoning of hot water to

the cold water supply.

c. #6 prevents ﬂow of cold water to the tempered

water supply. A draw of tempered water will not

result in ﬂow of cold water into the return loop.

Operation

1. During period of normal use (ﬁxtures on) — Circu-

lator is off. There is no ﬂow through #6, there is ﬂow

through #5 equal to the ﬂow at the ﬁxtures, there is

ﬂow through #3 and/or #4 equal to ﬂow at ﬁxture.

2. When all ﬁxtures are off — Circulator is off. There is

no ﬂow through #3, #4, #5 or #6. Water temperature

in piping is cooling.

3. When temperature at aquastat #2 falls 10° below

temperature to be maintained — Circulator is on.

There is ﬂow through #6 equal to the minimum

required by the mixing valve, ﬂow through #3 and

#4 equals the ﬂow of the circulator. There is no

ﬂow through #5.

4. Aquastat reaches temperature — Circulator is off.

There is no ﬂow through #3, #4, #5 or #6.

Potential problems

1. Missing check valves #3 or #4 — Extreme pressure drop can cause

reverse ﬂow of water; hot to cold supply or cold to hot supply.

2. Missing check valve #5 — Hot water can migrate from the water heater

back through the cold water supply.

3. Missing check valve #6 — Cold water can be forced back through the

tempered water supply when a ﬁxture is opened.

4. No aquastat #2 — Circulator runs continuously. Small amount of

water will pass through mixing valve. Eventually all hot water is ﬂow-

ing through valve. Recirculated water through cold port, hot water

through hot port.

5. Circulator too small — Mixing valve performance erratic.

Part number 633-500-230/0918

AQUA PRO

INDIRECT-FIRED WATER HEATERS — Product Manual

Figure 7 Zoning with circulators — direct-connected system piping

Boiler-side piping

Part number 633-500-230/0918

AQUA PRO

INDIRECT-FIRED WATER HEATERS — Product Manual

Maximum boiler-side ﬂow rate

Recommended ﬂow rate and minimum boiler-side pipe size

Select the boiler-side circulator carefully. The ﬂow rate

through the boiler side of the water heater must not

exceed the values below. Higher ﬂow rates could result

in an input above the rating of the T&P valve.

Models Aqua Pro

30 & 55 — do not exceed 12 GPM.

Models Aqua Pro

80 &119 — do not exceed 16 GPM.

Heater model GPM Pipe size Heater model GPM Pipe size

8.00 3/4”

14.00 1” *

8.00 3/4”

119

14.00 1” *

*Requires 1¼”x1” reducers at water heater

Notes

• Place circulators at begin-

nings of zones. Placing

them at the ends of zones

could result in heating idle

zones.

• Size manifold piping for

total ﬂow of all zone cir-

culators.

• Locate ﬂow / check valves

as close as possible to water

heater boiler side connec-

tions — to reduce heat loss

between cycles.

Wiring

• WMCR zone controller,

optional priority — Fig-

ure 25, page 23.

1. This drawing is conceptual

only. It shows representative

piping components and lay-

out. Weil-McLain does not

represent that this drawing

meets any particular me-

chanical or building codes.

The installer is responsible

for inclusion of all required

safety devices, or other mis-

cellaneous piping hardware

not shown on drawing. The

installer is responsible for

proper sizing / selection of

all hardware shown on this

diagram.

2. See boiler manual for spe-

ciﬁc details on installing the

boiler.

Boiler-side piping

(continued)

Figure 8 Zoning with circulators — primary/secondary system piping

Part number 633-500-230/0918

AQUA PRO

INDIRECT-FIRED WATER HEATERS — Product Manual

Notes

• Place circulators at begin-

nings of zones. Placing

them at the ends of zones

could result in heating idle

zones.

• Size manifold piping for

total ﬂow of all zone cir-

culators.

• Locate ﬂow / check valves

as close as possible to water

heater boiler side connec-

tions — to reduce heat loss

between cycles.

Wiring

• WMCR zone control-

ler, optional priority —

Figure 25, page 23.

Maximum boiler-side ﬂow rate

Recommended ﬂow rate and minimum boiler-side pipe size

Select the boiler-side circulator carefully. The ﬂow rate

through the boiler side of the water heater must not

exceed the values below. Higher ﬂow rates could result

in an input above the rating of the T&P valve.

Models Aqua Pro

30 & 55 — do not exceed 12 GPM.

Models Aqua Pro

80 &119 — do not exceed 16 GPM.

Heater model GPM Pipe size Heater model GPM Pipe size

8.00 3/4”

14.00 1” *

8.00 3/4”

119

14.00 1” *

*Requires 1¼”x1” reducers at water heater

1. This drawing is conceptual

only. It shows representative

piping components and lay-

out. Weil-McLain does not

represent that this drawing

meets any particular me-

chanical or building codes.

The installer is responsible

for inclusion of all required

safety devices, or other mis-

cellaneous piping hardware

not shown on drawing. The

installer is responsible for

proper sizing / selection of

all hardware shown on this

diagram.

2. See boiler manual for spe-

ciﬁc details on installing the

boiler.

Boiler-side piping

(continued)

Figure 9 Zoning with zone valves — direct-connected system piping

Part number 633-500-230/0918

AQUA PRO

INDIRECT-FIRED WATER HEATERS — Product Manual

Notes

• Place circulators at begin-

nings of zones. Placing

them at the ends of zones

could result in heating idle

zones.

• Size manifold piping for

total ﬂow of all zone cir-

culators.

• Locate ﬂow / check valves

as close as possible to water

heater boiler side connec-

tions — to reduce heat loss

between cycles.

Wiring

• WMZV zone control-

ler, optional priority —

Figure 26, page 23.

Maximum boiler-side ﬂow rate

Recommended ﬂow rate and minimum boiler-side pipe size

Select the boiler-side circulator carefully. The ﬂow rate

through the boiler side of the water heater must not

exceed the values below. Higher ﬂow rates could result

in an input above the rating of the T&P valve.

Models Aqua Pro

30 & 55 — do not exceed 12 GPM.

Models Aqua Pro

80 &119 — do not exceed 16 GPM.

Heater model GPM Pipe size Heater model GPM Pipe size

8.00 3/4”

14.00 1” *

8.00 3/4”

119

14.00 1” *

*Requires 1¼”x1” reducers at water heater

1. This drawing is conceptual

only. It shows representative

piping components and lay-

out. Weil-McLain does not

represent that this drawing

meets any particular me-

chanical or building codes.

The installer is responsible

for inclusion of all required

safety devices, or other mis-

cellaneous piping hardware

not shown on drawing. The

installer is responsible for

proper sizing / selection of

all hardware shown on this

diagram.

2. See boiler manual for spe-

ciﬁc details on installing the

boiler.

Boiler-side piping

(continued)

Figure 10 Zoning with zone valves — primary/secondary system piping

Part number 633-500-230/0918

AQUA PRO

INDIRECT-FIRED WATER HEATERS — Product Manual

Notes

• Place circulators at begin-

nings of zones. Placing

them at the ends of zones

could result in heating idle

zones.

• Size primary piping for

total ﬂow of all zone cir-

culators.

• Locate ﬂow / check valves

as close as possible to water

heater boiler side connec-

tions — to reduce heat loss

between cycles.

Wiring

• WMZV zone controller,

optional priority — Fig-

ure 26, page 23.

Maximum boiler-side ﬂow rate

Recommended ﬂow rate and minimum boiler-side pipe size

Select the boiler-side circulator carefully. The ﬂow rate

through the boiler side of the water heater must not

exceed the values below. Higher ﬂow rates could result

in an input above the rating of the T&P valve.

Models Aqua Pro

30 & 55 — do not exceed 12 GPM.

Models Aqua Pro

80 &119 — do not exceed 16 GPM.

Heater model GPM Pipe size Heater model GPM Pipe size

8.00 3/4”

14.00 1” *

8.00 3/4”

119

14.00 1” *

*Requires 1¼”x1” reducers at water heater

1. This drawing is conceptual

only. It shows representative

piping components and lay-

out. Weil-McLain does not

represent that this drawing

meets any particular me-

chanical or building codes.

The installer is responsible

for inclusion of all required

safety devices, or other mis-

cellaneous piping hardware

not shown on drawing. The

installer is responsible for

proper sizing / selection of

all hardware shown on this

diagram.

2. See boiler manual for spe-

ciﬁc details on installing the

boiler.

Boiler-side piping

(continued)

Figure 11 Dedicated single-boiler piping

Part number 633-500-230/0918

AQUA PRO

INDIRECT-FIRED WATER HEATERS — Product Manual

Notes

• Place circulators at beginnings

of zones. Placing them at the

ends of zones could result in

heating idle zones.

• Size manifold piping for total

ﬂow of all zone circulators.

• Locate flow / check valves as

close as possible to water heater

boiler side connections — to

reduce heat loss between cycles.

Wiring

• Connect water heater control

wires to boiler’s T-T terminals

or heat demand connection.

Maximum boiler-side ﬂow rate

Recommended ﬂow rate and minimum boiler-side pipe size

Select the boiler-side circulator carefully. The ﬂow rate

through the boiler side of the water heater must not

exceed the values below. Higher ﬂow rates could result

in an input above the rating of the T&P valve.

Models Aqua Pro

30 & 55 — do not exceed 12 GPM.

Models Aqua Pro

80 &119 — do not exceed 16 GPM.

Heater model GPM Pipe size Heater model GPM Pipe size

8.00 3/4”

14.00 1” *

8.00 3/4”

119

14.00 1” *

*Requires 1¼”x1” reducers at water heater

1. This drawing is conceptual

only. It shows representative

piping components and lay-

out. Weil-McLain does not

represent that this drawing

meets any particular me-

chanical or building codes.

The installer is responsible

for inclusion of all required

safety devices, or other mis-

cellaneous piping hardware

not shown on drawing. The

installer is responsible for

proper sizing / selection of

all hardware shown on this

diagram.

2. See boiler manual for spe-

ciﬁc details on installing the

boiler.

Boiler-side piping

(continued)

Figure 12 Multiple water heaters — domestic water piping

Figure 13 Alternate methods of revers-return piping and Easy-Fit® Manifold detail

Part number 633-500-230/0918

AQUA PRO

INDIRECT-FIRED WATER HEATERS — Product Manual

Failure to install automatic

mixing valve where recom-

mended can result in severe

personal injury or death.

1. This drawing is conceptual

only. It shows representative

piping components and lay-

out. Weil-McLain does not

represent that this drawing

meets any particular me-

chanical or building codes.

The installer is responsible

for inclusion of all required

safety devices, or other mis-

cellaneous piping hardware

not shown on drawing. The

installer is responsible for

proper sizing / selection of

all hardware shown on this

diagram.

2. Wire water heater controls

in series when connecting

to boiler controller or boiler

T-T terminals.

3. Install automatic mixing

valve at either the system

hot water connection or at

each water heater.

4. See page 8 through page 10

for additional recirculation

information and piping

details.

Boiler-side piping

(continued)

Figure 14 Multiple water heaters and dedicated multiple boilers — boiler water piping

Part number 633-500-230/0918

AQUA PRO

INDIRECT-FIRED WATER HEATERS — Product Manual

Notes

• See legend and details in

Figure 12, page 16.

1. This drawing is conceptual

only. It shows representative

piping components and lay-

out. Weil-McLain does not

represent that this drawing

meets any particular me-

chanical or building codes.

The installer is responsible

for inclusion of all required

safety devices, or other mis-

cellaneous piping hardware

not shown on drawing. The

installer is responsible for

proper sizing / selection of

all hardware shown on this

diagram.

2. See boiler manual for spe-

ciﬁc details on installing the

boiler.

Connecting to a low-pressure steam boiler

Special considerations

When designing steam and domestic hot water systems, there are some

key issues that must be taken into consideration during the initial de-

sign phase. By designing the system properly from the start, you can

avoid problems and have a hot water loop in a steam boiler system.

• The domestic water demand should preferably not exceed 1/3

of the steam boiler capacity. Larger demand may cause difﬁculty

obtaining steam as needed.

• Keep the loop temperature below the ﬂash point. Flashing can result

in noise and circulator damage or shortened life.

• Be sure the loop is completely closed, with no automatic or manual

air vents, or anything that could allow air to enter the system when

the pump shuts off.

• Pipe supply from one side of the boiler, return to the opposite

side as shown.

• Supply from a tapping that is high enough to prevent introducing

sediment into the piping and circulator yet still below the water

line. Avoid the mud leg of the boiler.

• Use an all bronze circulator.

• Avoid wet rotor circulators. Select a circulator with a large

volute, such as a typical 3-piece circulator.

• This will reduce clogging and will resist the corrosion potential

from the steam condensate.

• Make sure the circulator is properly sized. If the circulator runs too

far out on its curve, cavitation potential increases signiﬁcantly.

• Use (2) ﬂow / check valves as shown to reduce the potential for

gravity circulation.

• DO NOT use spring-loaded check valves in place of the

ﬂow / check valves shown in Figure 16, page 19.

Installation and start-up of water heaters

connected to steam boilers

1. See Figure 16, page 19, for suggested piping schematic.

2. Pipe the domestic water connections to the water heater per “Do-

mestic water piping,” page 6.

Boiler connections for the water heater must be below

the water line. DO NOT use the gauge glass tapping or a

low water cut-off tapping if a LWCO is installed there.

For steam piping, refer to the steam boiler manual.

DO NOT install an air vent anywhere in the piping. The

piping must be air tight.

3. Wire the water heater and circulator to the boiler per suggested

wiring in Figure 15. The water heater must be wired and ready to

operate before proceeding. Note that the L4006A aquastat is located

in the boiler and sets a boiler operating temperature when there is

no call for steam heating.

To ﬁll the boiler and water heater:

1. Follow the procedure given in Figure 16, page 19 to ﬁll the water

heater piping.

2. Follow the boiler manual instructions to ﬁll the steam boiler.

Figure 15 Typical wiring for connection to low-pressure

steam boiler

Install the Honeywell L4006A aquastat in the boiler,

below the water line. Set for a temperature of 180 to

190°F to control boiler temperature when there is no

call for steam heating.

Valve 7, the memory stop valve, must

be supplied, piped and adjusted as in-

structed. This valve allows cooler return

water to mix with the hot water from

the steam boiler. The valve is set to yield

approximately 180°F water entering the

circulator. Higher temperature water

could cause cavitation in the circulator,

damaging the impeller and shortening

circulator life.

DO NOT connect the piping to the boil-

er’s mud leg. This would probably cause

excessive sediment to enter the water

heater piping, damaging the circulator.

The strainer in the circulator suction line

must be serviced regularly. NOTE that

noise from the circulator is a likely sign

that the strainer is restricting circulator

ﬂow, causing cavitation.

Part number 633-500-230/0918

AQUA PRO

INDIRECT-FIRED WATER HEATERS — Product Manual

Connecting to a low-pressure steam boiler

(continued)

Figure 16 Low pressure steam boiler application — Domestic water heating using water pumped from steam boiler

Part number 633-500-230/0918

AQUA PRO

INDIRECT-FIRED WATER HEATERS — Product Manual

Notes

• Locate ﬂow / check valve as

close as possible to water

heater boiler side connec-

tions — to reduce heat loss

between cycles.

Use memory stop valve 7 to

blend some of the water re-

turning to the boiler with the

hot water coming from the

boiler. This will reduce the

possibility of ﬂashing (cavita-

tion) in the circulator. Slowly

open valve 7 until temperature

gauge 8 reads 200°F.

Set the memory stop on valve 7

after adjusting. Attach a tag to

the valve warning no to close

or change valve position.

NOTE —

If the boiler water

level should drop below ei-

ther the water heater boiler

water supply or return line,

the filling procedure will

have to be repeated.

1. This drawing is conceptual

only. It shows representative

piping components and lay-

out. Weil-McLain does not

represent that this drawing

meets any particular me-

chanical or building codes.

The installer is responsible

for inclusion of all required

safety devices, or other mis-

cellaneous piping hardware

not shown on drawing. The

installer is responsible for

proper sizing / selection of

all hardware shown on this

diagram.

2. See boiler manual for spe-

ciﬁc details on installing the

boiler.

Filling the piping

1. Parts of the boiler water piping to the water

heater may be higher than the water line,

depending on the height of the water heater

boiler supply connection. The piping must be

air tight to prevent air from pocketing at the

top of the piping, stopping ﬂow.

2. The boiler MUST be filled and ready to

operate before proceeding. Follow the boiler

manual to ﬁll the boiler.

3. Follow the procedure below to ﬁll the boiler-

to-water heater piping. See Figure 16.

Step 1 Close isolation valves 5 and 6 to isolate

the boiler.

Step 2 Close valve 3 and open valve 4. Con-

nect a cold water supply hose to

valve 3. Connect a hose from valve 4

to a drain able location.

Step 3 Close valve 10. Open valve 7.

Step 4 Open valve 3. Water will ﬂow through

valve 7 and out through valve 4 to

drain. Open valve 11. Let water run

until all air has been removed from

the line through valve 11. Close valve

11. Close valve 4. Then close valve 3.

Step 5 Close valve 7. Then open valve 10.

Step 6 Open valve 3. Water will ﬂow through

the circulator line, the water heater

coil and the return piping, then out

through valve 4 to drain. Let water run

until all air has been removed from the

line. Close valve 4. Then close valve 3.

Remove hoses.

Step 7 Follow the instructions in “Water

heater ﬁlling and start-up,” page 26,

to ﬁll the domestic water side of the

water heater.

Step 8 Open valve 7 about ¼ turn for an

initial setting.

Step 9 Open isolation valves 5 and 6. Make

sure the boiler water level is correct

per the boiler manual.

Step 10 Start the boiler per instructions given

in the boiler manual. Allow boiler to

begin steaming.

Step 11 Start the DHW circulator. Watch the

temperature at gauge 8. Adjust valve 7

until gauge 8 reads about 180°F with

system at steady operation.

Step 12 Continue checking under varying

DHW demand conditions to ensure

system will operate as required.

Part number 633-500-230/0918

AQUA PRO

INDIRECT-FIRED WATER HEATERS — Product Manual

Electrical shock hazard — Can cause

severe personal injury, death or substantial

property damage. Disconnect power before

installing and / or servicing.

Wiring requirements

1. All wiring must be a minimum of 18 gauge and installed

in accordance with:

• U.S.A. — National Electrical Code, ANSI/NFPA 70

- latest edition and any other national, state or local

code requirements having jurisdiction.

• Canada — CSA C22.1 Canadian Electrical Code Part

1 - latest edition and any other national, provincial and

local code requirements having jurisdiction.

2. If original wire as supplied with appliance must be re-

placed, Type 90° C or its equivalent must be used.

3. Refer to control component instructions packed with

boiler for application information.

4. An optional service switch may be installed in water heater

electrical circuit. This switch would only shut off the water

heater, not the home heating system. Do not shut off water

heater if there is a chance of freezing.

5. All electrical contacts are shown with no power applied

— off-the-shelf condition.

Circulators

Size priority relay for total amp draw of all circulators.

Zone Valves

Size transformer for maximum load of all zone valves.

Wiring to the water heater

Field connections to the water heater control are for 24VAC

only, connecting to the two-pole terminal block shown in

Figure 17.

Wiring options

1. This manual shows wiring only for use of typical Circula-

tor Zone Controller or Zone Valve Zone Controller, wire

per manufacturer’s instructions.

2. Other wiring methods may be acceptable and are left to

the installer.

Use domestic priority

1. When possible, set controls to provide domestic priority

— that is, on a call for domestic water the control switches

from space heating to DHW only.

2. Domestic priority ensures the fastest possible response to

the DHW call for heat.

3. The smaller the water heater, the greater the need for

rapid response.

Figure 17 Wiring the control “General Connection”

Figure 18 Wiring tank control to the AquaBalance

boiler control.

Boiler-side wiring and controls

1. Connect a 24VAC power source to the “24VAC Input” termi-

nals.

2. Connect the “Output Contacts” to the zone or boiler control’s

domestic water input.

3. Eliminate stray voltage in the power circuit by connecting the

24VAC power to AC2 and grounding AC1. Conﬁrm correct con-

nections by verifying 24VAC between AC1 and AC2.

The “Output Contacts” are isolated contacts that close

when the control calls for heat.

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Weil-McLain 633500203 User manual

Brand: Weil-McLain

Model: 633500203

Category: Water heaters & boilers

Type: User manual

This manual is also suitable for

Aqua Pro

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Weil-McLain 633500203 User manual

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